Hydraulic components and methods of manufacturing
A spiral wound header ring is provided. The spiral wound header ring comprises at least one outer fabric layer and at least one spiral of inner fabric and rubber. The spiral wound header ring further may have a sealing surface that extends from a rearward facing surface to the forward facing annular, radially extending, surface.
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The present application claims priority to U.S. Provisional Patent Application Ser. No. 62/548,725, titled Hydraulic components and methods of manufacturing, filed Aug. 22, 2017, which is incorporated herein by reference as if set out in full.
BACKGROUNDMany fluid systems have pumps, valves, rams, etc. (generically “fluid equipment”) that provide for reciprocal or rotating movement of a piston rod, valve stem, or the like (hereinafter referred to generically as a “rod”). The surface of the rod provides a leak path between the high-pressure side and the low-pressure side of the fluid equipment. To inhibit leakage, the rods move through stuffing boxes having packing or packing rings. The packing forms a seal with the rod to inhibit leakage and the like.
One popular stuffing box configuration was originally introduced by Garlock, Inc. (now known as Garlock Sealing Technologies, LLC.) in the 1960's and is the subject matter of U.S. Pat. No. 3,013,830, the disclosure of which is incorporated herein by reference as if set out in full. The stuffing box or packing assembly of U.S. Pat. No. 3,013,830 provides one or more fabric wrapped pressure seals that have a V-shape or Chevron shape. The pressure seal comprises a core of material, such as a homogeneous elastomeric or polymeric material or a fabric reinforced elastomeric or polymeric material, which is typically rubber or fiber reinforced rubber, whether natural or synthetic. The core of rubber is subsequently wrapped with an outer fabric. U.S. Pat. No. 3,013,830 provides that the one or more fabric wrapped pressure seals are typically stacked on an adapter ring that facilitates providing a compression force to seal the one or more fabric wrapped pressure seals against the rod.
U.S. Pat. No. 4,440,404, issued to Halliburton Company, which is incorporated herein by reference as if set out in full, modified the stuffing box assembly of U.S. Pat. No. 3,013,830. U.S. Pat. No. 4,440,404 introduced a header ring with an inwardly radially extending convex sealing surface. The inwardly radially extending convex sealing surface acted as a seal and wiper against the rod to inhibit leakage from the fluid medium and inhibited particles carried in the fluid medium from contacting the one or more fabric wrapped pressure seals stacked behind the header ring reducing wear due to abrasion and the like.
Unfortunately, the systems of today operate at high pressures with very corrosive fluids (both chemically and mechanically corrosive). Thus, the header ring is exposed to a harsh operating environment that results in wear on the header ring. In particular, the elastomeric header ring of U.S. Pat. No. 4,440,404 experiences wear at the junction between the pedestal or heel of the header ring and the inwardly radially extending convex sealing surface. To resist wear, it would have been obvious to either load the rubber of the header ring with reinforcing fiber, to wrap the elastomeric header ring with a fabric similar to the one or more pressure seals described above, or a combination thereof.
None of these options, however, is entirely satisfactory. To load the elastomeric core or rubber core with sufficient fiber reinforcement to withstand today's pressures and media, the header ring becomes over stiff. Moreover, simply placing fabric around the header ring has been unsatisfactory as the header ring still suffers from less than optimal performance.
Thus, against the above background, a new core different than a homogenous elastomeric core or a fiber reinforced elastomeric core is needed.
SUMMARYThis Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary, and the foregoing Background, is not intended to identify key aspects or essential aspects of the claimed subject matter. Moreover, this Summary is not intended for use as an aid in determining the scope of the claimed subject matter.
In certain aspects of the technology, a header ring is provided. The header ring is formed using a spiral winding technique to form a spiral wound header ring. The header ring includes at least one outer layer of fabric that envelops a core. The core comprises at least one inner layer of fabric, and a rubber or polymer layer. The rubber or polymer layer may include, among other things, fiber reinforcement. In at least one embodiment, the outer layer of fabric is integral with the inner layer of fabric.
In certain embodiments, the header ring comprises a forward facing annular, radially extending surface having an inner diameter edge and a sealing surface having an annular, radially and axially extending, convex sealing surface having a forward facing edge. The inner diameter edge and the forward facing edge abut, which eliminates the conventional junction of current header rings and reduces nibbling. In certain aspects, the inner diameter edge and the forward facing edge abut to form an obtuse angle. The obtuse angle is generally between about 100 and 130 degrees. In certain embodiments, the obtuse angle is between about 115 and 125 degrees. In still other embodiments, the obtuse angle is about 120 degrees. In certain aspects, the annular, radially and axially extending, convex sealing surface comprises at least one radius of curvature. In other aspects, the annular, radially and axially extending, convex sealing surface comprises a plurality of radii of curvature. In still other aspects, the annular, radially and axially extending, convex sealing surface comprises at one linear portion.
The technology of the present application also provides a method for making a header ring. The method for making the header ring includes providing a first layer wherein the first layer comprises a fabric and a second layer on the first layer wherein the second layer comprises a rubber. The construct or composite of the first and second layers are rolled to form a cylinder of material that is cut to an appropriate length. The cut cylinder of material is placed into a mold and formed into a header ring, when the mold is subsequently removed. In certain aspects the second layer is provided on only a portion of the first layer, which allows rolling of the cylinder to have a plurality of outer layers of fabric.
The technology of the present application provides for a packing system including at least one pressure ring and a header ring. The header ring including a plurality of outer fabric layers and a header ring core enveloped by the plurality of outer fabric layers, wherein the plurality of outer fabric layers and the header ring core form a shape. The header ring includes an annular, radially extending forward facing surface having an inner diameter edge and an outer diameter edge. An annular, axially extending surface having a forward facing edge and a rearward facing edge where the forward facing edge abuts the outer diameter edge of the annular, radially extending forward facing surface. At least one annular and radially extending rearward pressure ring surface having an outer diameter edge and an inner diameter edge where the outer diameter edge abuts the rearward facing edge of the annular, axially extending surface. At least one sealing surface radially and axially extending having a rearward edge and a forward edge wherein the rearward edge abuts the inner diameter edge of the at least one annular and radially extending rearward pressure ring surface and the forward edge abuts the inner diameter edge of the annular, radially extending forward facing surface. The header ring core comprises at least one fabric layer and at least one polymer layer.
Non-limiting and non-exhaustive embodiments of the present invention, including the preferred embodiment, are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.
The technology of the present application will now be described more fully below with reference to the accompanying figures, which form a part hereof and show, by way of illustration, specific exemplary embodiments. These embodiments are disclosed in sufficient detail to enable those skilled in the art to practice the technology of the present application. However, embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. The following detailed description is, therefore, not to be taken in a limiting sense.
The technology of the present application is described with specific reference to stuffing boxes associated with reciprocating pumps. However, the technology described herein may be used for other fluid equipment, such as for example, valves, rams, and the like. Moreover, the technology of the present application will be described with relation to exemplary embodiments. The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Additionally, unless specifically identified otherwise, all embodiments described herein should be considered exemplary.
With reference now to
With reference now to
As mentioned above, various obvious attempts to reduce the wear on header rings such as header rings 10 and 30 have been less than satisfactory. Thus, the technology herein provides an improved header ring.
The annular header ring 40 as shown in
For completeness, the annular header ring 40 has a pedestal or heel portion 46 with a forward facing annular, radially extending, surface 52. An annular, axially extending, surface 54 extends along the cylindrical wall of the stuffing box. The rearward facing surfaces of the header ring 40 are generally formed by annular, axially and radially extending, pressure ring surfaces 56 and 58 that converge at a bead 60. An annular, radially and axially extending, convex sealing surface 48 extends from annular, axially and radially extending, surface 58, which terminates at a junction 44. An annular, axially extending, pedestal surface 62 originates at junction 44 and extends axially to the forward facing flat annular, radially extending, surface 52. Optionally, the annular header ring may further include an outer layer 41 over any portion thereof. In a preferred embodiment, the outer layer 41 encompasses the entire annular header ring 40. The outer layer 41 may be an external layer or layers of frictioned rubber, which is a fabric that has been smeared with rubber, typically through a calendaring process, other fabrics, or a combination thereof.
As mentioned above, the junction 44 provides a location for wear. The wear is due to a high stress concentration after the installation of the annular header ring 40 in a stuffing box.
Providing the annular header ring 70 with a linear surface 82 reduces or eliminates the nibbling and premature failure associated with conventional header rings. The structure of the overall design provides less body roll, which is the rotation of the sealing element as the reciprocating stem moves. By stiffening the ring it rotates less, and also engages the pressure ring above it axially. The annular header ring also has less nibbling, improved sealing, and improved excluding, which means in the art that the header ring 70 excludes particulates that are in the media, which is often different than the media. The annular header ring also has improved recovery and less shuttling (which is a term of art in the industry relating to movement of the overall packing assembly).
With reference now to
After obtaining a sheet of the spiral wound material 42, the sheet is rolled into a cylinder 116 (or a tube 116) as shown in
Although the technology has been described in language that is specific to certain structures and materials, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific structures and materials described. Rather, the specific aspects are described as forms of implementing the claimed invention. Because many embodiments of the invention can be practiced without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. Unless otherwise indicated, all numbers or expressions, such as those expressing dimensions, physical characteristics, etc. used in the specification (other than the claims) are understood as modified in all instances by the term “approximately.” At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the claims, each numerical parameter recited in the specification or claims which is modified by the term “approximately” should at least be construed in light of the number of recited significant digits and by applying ordinary rounding techniques. Moreover, all ranges disclosed herein are to be understood to encompass and provide support for claims that recite any and all subranges or any and all individual values subsumed therein. For example, a stated range of 1 to 10 should be considered to include and provide support for claims that recite any and all subranges or individual values that are between and/or inclusive of the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less (e.g., 5.5 to 10, 2.34 to 3.56, and so forth) or any values from 1 to 10 (e.g., 3, 5.8, 9.9994, and so forth).
Claims
1. A header ring, comprising:
- a forward facing portion with an annular forward facing radially extending surface with an inner diameter edge;
- an annular, radially and axially extending, convex sealing surface extends from a rearward facing surface to the inner diameter edge of the forward facing portion forming an obtuse angle between the forward facing portion and the annular, radially and axially extending, convex sealing surface;
- at least one outer layer of fabric; and
- a spiral wound core contained by the at least one outer layer of fabric,
- the spiral wound core alternatingly comprising: a plurality of inner layers of fabric, and a rubber layer interspersed between the plurality of inner layers of fabric.
2. The header ring of claim 1, wherein the at least one outer layer of fabric comprises a plurality of outer layers of fabric.
3. The header ring of claim 2 wherein the plurality of inner layers of fabric are integrally coupled to the at least one outer layer of fabric.
4. The header ring of claim 1 wherein the rubber is fiber reinforced rubber.
5. The header ring of claim 1 wherein the annular, radially and axially extending, convex sealing surface comprises at least one radius of curvature.
6. The header ring of claim 5 wherein the annular, radially and axially extending, convex sealing surface comprises at least one linear portion.
7. The header ring of claim 6 wherein the linear portion forms an obtuse angle with the forward facing annular, radially extending surface.
8. The header ring of claim 7 wherein the obtuse angle is between 100 and 130 degrees.
9. The header ring of claim 1 wherein the obtuse angle is between about 115° and 125°.
10. The header ring of claim 1 wherein the obtuse angle is about 120°.
11. A packing system for a compressor pump including at least one pressure ring and at least one header ring, the header ring for the compressor pump comprising:
- a plurality of outer fabric layers;
- a header ring core enveloped by the plurality of outer fabric layers, wherein the plurality of outer fabric layers and the header ring core form a shape for the header ring comprising:
- an annular, radially extending forward facing surface having an inner diameter edge and an outer diameter edge;
- an annular, axially extending surface having a forward facing edge and a rearward facing edge where the forward facing edge abuts the outer diameter edge of the annular, radially extending forward facing surface;
- at least one annular and radially extending rearward pressure ring surface having an outer diameter edge and an inner diameter edge where the outer diameter edge abuts the rearward facing edge of the annular, axially extending surface; and
- at least one sealing surface radially and axially extending having a rearward facing edge and a forward facing edge wherein the rearward facing edge abuts the inner diameter edge of the at least one annular and radially extending rearward pressure ring surface and the forward facing edge abuts the inner diameter edge of the annular, radially extending forward facing surface forming an obtuse angle between the forward facing surface and the sealing surface; and
- wherein the header ring core comprises at least one fabric layer and at least one polymer layer.
12. The packing system of claim 11 wherein the polymer layer is selected from a group of polymers consisting of: natural rubber, synthetic rubber, or a combination thereof.
13. The packing system of claim 12 wherein the polymer layer comprises a fiber reinforced polymer.
14. The packing system of claim 12 comprising an obtuse angle formed where the forward edge of the at least one sealing surface abuts the inner diameter edge of the annular, radially extending forward facing surface.
15. The packing system of claim 14 wherein the obtuse angle is between about 100 and 130 degrees.
16. The packing system of claim 15 wherein the at least one sealing surface comprises at least one radius of curvature.
17. The packing system of claim 16 wherein the at least one sealing surface comprises at least one linear portion.
18. A header ring, comprising:
- at least one outer layer of fabric; and
- a spiral wound core contained by the at least one outer layer of fabric,
- the spiral wound core alternatingly comprising: a plurality of inner layers of fabric, and a rubber layer interspersed between the plurality of inner layers of fabric, wherein the plurality of inner layers of fabric are contiguous and originate at about a center of the header ring and spiral outwards and wherein the at least one outer layer of fabric is contiguous with the plurality of inner layers of fabric.
19. The header ring of claim 18 wherein the fabric is selected from the group of fabrics consisting of woven textiles or non-woven textiles.
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Type: Grant
Filed: Aug 20, 2018
Date of Patent: Oct 12, 2021
Assignee: Garlock Sealing Technologies, LLC (Palmyra, NY)
Inventors: Randy Matthys (Palmyra, NY), Chad Yoder (Palmyra, NY), Michael McNally (Palmyra, NY), Louis Mattina (Palmyra, NY)
Primary Examiner: Gilbert Y Lee
Application Number: 16/105,590
International Classification: F16J 15/20 (20060101); F04B 53/16 (20060101); F16J 15/26 (20060101); F16J 15/16 (20060101); F16J 15/3268 (20160101); F04B 53/22 (20060101);